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  • #61
    Nice - never thought of fitting it that way round.

    One thing though - fitting it the wrong way on those riv nuts will rip them out fairly quickly - if you've not already done so, fit longer bolts that stick out the top of the plate then add some penny washers and some nuts, they will serve to spread the load, compress the riv nut the way it should be loaded and stop it fretting out of the hole.

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    • #62
      Originally posted by regcheeseman View Post
      Nice - never thought of fitting it that way round.

      One thing though - fitting it the wrong way on those riv nuts will rip them out fairly quickly - if you've not already done so, fit longer bolts that stick out the top of the plate then add some penny washers and some nuts, they will serve to spread the load, compress the riv nut the way it should be loaded and stop it fretting out of the hole.
      Do you know what - I woke up thinking the very same thing... 👍

      I tried the pedal a few times, there's a considerable amount of flex in the bracket, which did make me ponder it's reliability.

      I've put up the picture of the two throttle pedals​ side by side, should make it easier to modify the cable one to accept the potentiometer. If you want a measurement or two just give me a shout - pedal box isn't back in the van yet. ☺

      Sent from my Moto G (4) using Just T4s
      '00 1.9TDI LWB, '87 Mk2 Golf 16v

      Wheel or tyre question? Just ask, it's what i do!

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      • #63
        Originally posted by Adventure Van View Post
        Do you know what - I woke up thinking the very same thing... ��

        I tried the pedal a few times, there's a considerable amount of flex in the bracket, which did make me ponder it's reliability.

        I've put up the picture of the two throttle pedals​ side by side, should make it easier to modify the cable one to accept the potentiometer. If you want a measurement or two just give me a shout - pedal box isn't back in the van yet. ☺

        Sent from my Moto G (4) using Just T4s
        No need for measurements, take a look at the sausage swap thread - made my bracket from scratch last night (and remembered to take pictures )

        No flex in my bracket, and there is quite a lot of load required to rotate the TPS isn't there!

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        • #64
          I don't have your fabrication skills I'm afraid Reg...

          More work has been done over the weekend! 👍



          Pedal box back in.



          With clutch reinforcing plate fitted! 👍



          Mk4 golf lower grill section cut into bumper.



          Pair of recon driveshafts installed, and brakes serviced.

          Sent from my Moto G (4) using Just T4s
          '00 1.9TDI LWB, '87 Mk2 Golf 16v

          Wheel or tyre question? Just ask, it's what i do!

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          • #65


            Front mount intercooler finally on! 👍😁

            Sent from my Moto G (4) using Just T4s
            '00 1.9TDI LWB, '87 Mk2 Golf 16v

            Wheel or tyre question? Just ask, it's what i do!

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            • #66
              Yay - another front mount.

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              • #67


                Purple silicone intercooler pipes! 👍

                Sent from my Moto G (4) using Just T4s
                '00 1.9TDI LWB, '87 Mk2 Golf 16v

                Wheel or tyre question? Just ask, it's what i do!

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                • #68
                  Wiring loom starting to go in...



                  If you've unplugged the expansion bottle sensor, and you didn't label it, this is what it plugs back into:



                  Just waiting on more link pipes for the intercooler and the air intake (they sent the wrong size... Grrrrr).



                  Sent from my Moto G (4) using Just T4s
                  '00 1.9TDI LWB, '87 Mk2 Golf 16v

                  Wheel or tyre question? Just ask, it's what i do!

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                  • #69
                    Not much to see here, but I've amalgamated the two alternator to battery leads, giving me the necessary 'w' terminal connection for the rev counter.
                    Trying to keep the wiring as factory as possible...



                    Sent from my Moto G (4) using Just T4s
                    '00 1.9TDI LWB, '87 Mk2 Golf 16v

                    Wheel or tyre question? Just ask, it's what i do!

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                    • #70
                      More progress today...

                      Wiring loom taped up, and plugged in.
                      Exhaust 'c' clips back on.
                      Intercooler plumbed in.



                      New silicone vacuum lines installed for inlet to ECU and boost control valve.



                      Sent from my Moto G (4) using Just T4s
                      '00 1.9TDI LWB, '87 Mk2 Golf 16v

                      Wheel or tyre question? Just ask, it's what i do!

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                      • #71
                        Looking good mate!


                        Sent from my iPhone using Just T4s

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                        • #72
                          Originally posted by Jonnybigballs85 View Post
                          Looking good mate!


                          Sent from my iPhone using Just T4s
                          Thanks mate... On the driveway again today. Hopefully it'll be running by tea time... 👍

                          Pondering power steering cooler pipework now, doesn't seem to want to go back in properly... 🤔

                          Sent from my Moto G (4) using Just T4s
                          '00 1.9TDI LWB, '87 Mk2 Golf 16v

                          Wheel or tyre question? Just ask, it's what i do!

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                          • #73
                            Well it runs!! 👍👍

                            A few niggly bits to sort out...

                            Slight oil leak from oil filter housing.
                            Rev counter doesn't work till you blip the throttle - oil light flashes till you do also.
                            Exhaust smell in engine bay - think I need to horse up the down pipe bolts a little more.

                            Other than that I'm dead happy! 😁😁

                            Sent from my Moto G (4) using Just T4s
                            '00 1.9TDI LWB, '87 Mk2 Golf 16v

                            Wheel or tyre question? Just ask, it's what i do!

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                            • #74
                              That's great news buddy. Any pics?


                              Sent from my iPhone using Just T4s

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                              • #75
                                Didn't take many today, as there wasn't much to see that was different...

                                This was yesterday;



                                Today it looks more like this;



                                I'm not putting the bumper back on untill I've sorted the oil leak. The intercooler will have to come off again so I can get to it also.

                                Sent from my Moto G (4) using Just T4s
                                '00 1.9TDI LWB, '87 Mk2 Golf 16v

                                Wheel or tyre question? Just ask, it's what i do!

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